Powerjack Rebuild for Models 100 and 200.
| The Powerjack Model 100 is ready for disassembly. |  |
| First, remove the gear shaft nut. |  |
| Push, and pull out the pawl pin. |  |
| Remove the handle from the Powerjack and the ratchet shaft from the handle. |  |
| Set aside the ratchet spring and gear for use during reassembly. |  |
| Straighten and remove the cotter pin from the pawl pin. |  |
| Next, remove the 2 pawl springs. |  |
| Pull out the pawl pin and bushing which hold the 2 ratchet pawls. |  |
| Remove both pawls 1 and 2. |  |
| Remove the plastic cap screw from the end of the rack. |  |
| Slide the gear rack out of the base. |  |
| Powerjack is now ready for reassembly. |
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| Check all parts for wear and replace as necessary. |  |
| Slide gear rack into the Powerjack base. |  |
| Mount the plastic cap screw to the end of the rack and tighten. |  |
| Place both pawl 1 and pawl 2 into the Powerjack base. |  |
| Insert the pawl pin through the pawl bushing. |
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| Push the pin and bushing through the base and the ratchet pawls. |
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| Insert and secure the cotter pin through the end of the pawl pin. |
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| Insert the pawl springs for both pawl 1 and pawl 2. |
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| Insert the gear while holding the pawls forward. |
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| Take note of the flat side of the ratchet shaft. |
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| Slide the ratchet shaft through the end of the handle. |
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| Place the handle into the base while lining up the shaft and the gear. |
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| The flat side of the shaft should be up against the gear teeth. |
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| Next is the gear shaft: note the head has one flat side. |
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| The flat side of the gear shaft head will line up with the flat edge of the Powerjack base. |
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| Push the gear shaft through the base. |
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| Reinstall the gear shaft nut. |
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| Tighten firmly. |
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| Next we'll add the ratchet spring. |
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| Note the straight end in the middle and the looped end to the right. |
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| With the spring around the shaft and through the slot, hook the looped end around the handle base. |
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| Move the handle to check that the ratchet function is now working. |
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| Powerjack is now ready for functional testing. |
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| Test that the handle and gear pushes the rack outward. |
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| Push the handle full forward to release the
ratchet pawls. Rack should now slide freely. |
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| Powerjack rebuild is now complete. |
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